Flexible connectors and methods of manufacturing same

ABSTRACT

A flexible connector comprises a length of corrugated tubing having a distal end and an end piece having a proximal end. The proximal end of the end piece is engaged with the distal end of the length of corrugated tubing and a length of polymeric tubing is utilized to initially retain the end piece and the length of corrugated tubing in engagement with one another. A length of mesh tubing may be extended along the length of corrugated tubing and around the exterior of the length of polymeric tubing. A sleeve is positioned in alignment with the length of polymeric tubing, with the proximal end of the end piece, and with the distal end of the length of corrugated tubing. The sleeve is crimped to permanently retain the proximal end of the end piece in engagement with the distal end of the length of corrugated tubing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of application Ser. No.10/689,279 filed Oct. 20, 2003, now U.S. Pat. No. 7,140,648, the entirecontents of which are incorporated herein by reference.

TECHNICAL FIELD

This invention relates generally to flexible connectors of the typeutilized in conjunction with fire hoses and in similar applications, andmore particularly to flexible connectors which are less expensive tomanufacture as compared with the prior art.

BACKGROUND AND SUMMARY OF THE INVENTION

Referring to FIGS. 1A and 1B, there is shown a typical prior artflexible connector 10. The flexible connector 10 includes a corrugatedtube 12. The function of the tube 12 is to contain fluids passingthrough the flexible connector 10 while affording flexibility thereto.The tube 12 does not have sufficient bursting strength to withstand thehigh pressures often associated with typical flexible connectorapplications.

Therefore, the flexible connector 10 may also include a mesh tube 14which surrounds the tube 12. The function of the mesh tube 14 is toprovide the necessary bursting strength without compromising theflexibility of the tube 12. As is known to those skilled in the art, thestainless steel mesh tube 14 can be omitted in low pressureapplications.

The tubes 12 and 14 extend the entire length of the flexible connector10. At each end thereof there is provide a sleeve 16. The function ofthe sleeve 16 is to facilitate manipulation of the flexible connector 10both during connection thereof to other instrumentalities and duringuse.

FIGS. 1A and 1B also illustrate the construction of the flexibleconnector 10. First, the corrugated tube 12, the mesh tube 14, and thesleeve 16 are assembled as shown in FIG. 1A, that is, with the endsthereof substantially aligned. Thereafter, a weldment 18 is formedaround the ends of the tube 12, the tube 14, and the sleeve 16. Theweldment 18 secures all three components one to another. Of course, inapplications in which the tube 14 is omitted, only the tube 12 and thesleeve 16 are secured by the weldment 18.

Following the welding step shown in FIG. 1A, a weldment 20 is employedto secure an end piece 22 at each end of the flexible connector 10. Aswill be appreciated by those skilled in the art, the end piece 22 shownin FIG. 2A is representative only. In actual practice numerous types andkinds of end pieces are utilized in the construction of flexibleconnectors.

As will therefore be understood, the construction of a prior artflexible connector requires two welding steps both of which must beprecisely executed in order that the flexible connector will be properlyconstructed. The type of welding required to properly assemble aflexible connector of the kind shown in FIGS. 1A and 1B requires theservices of highly skilled technicians having years of experience. Itwill therefore be understood that the type of flexible connector shownin FIGS. 1A and 1B and described hereinabove is relatively expensive tomanufacture.

The present invention comprises improvements in flexible connectordesign and construction which overcome the foregoing and otherdifficulties which have long since characterized the prior art. Inaccordance with the broader aspects of the invention, a flexibleconnector includes a corrugated tube and an end piece. The proximal endof the end piece and the distal end of the corrugated tube are engagedwith one another. A length of polymeric tubing is then extended over theadjacent ends of the corrugated tubing and the end piece, therebyretaining the ends of the length of corrugated tube and of the end piecein engagement with one another.

The length of polymeric tubing may be received within a length of meshtubing which extends the entire length of the corrugated tube and alsoextends over the proximal end of the end piece. A sleeve having an axiallength approximating the axial length of the polymeric tubing is thenextended over the end of the mesh tube. The sleeve is then crimpedthereby completing the manufacture of the flexible connector.

In low pressure applications, the length of mesh tubing may be omitted.In such instances the sleeve extends over the length of polymerictubing. Following the positioning of the stainless steel sleeve inalignment with the length of polymeric tubing and with the engaged endsof the corrugated tube and the end piece, the sleeve is crimped therebycompleting the manufacture of the flexible connector.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the invention may be had by referenceto the following Detailed Description when taken in conjunction with theaccompanying Drawings, wherein:

FIG. 1A is a perspective view illustrating a prior art flexibleconnector;

FIG. 1B is a perspective view further illustrating the prior artflexible connector of FIG. 1A;

FIG. 2 is an exploded perspective view illustrating a flexible connectorcomprising a first embodiment of the present invention and furtherillustrating the initial steps in the manufacture thereof;

FIG. 3 is a perspective view illustrating the flexible connector of FIG.2 following the completion of the manufacturing steps illustratedtherein;

FIG. 4 is a perspective view illustrating final steps in the manufactureof the flexible connector of FIG. 2;

FIG. 5 is a perspective view illustrating a flexible connectorcomprising a second embodiment of the present invention and furtherillustrating initial steps in the manufacture thereof; and

FIG. 6 is a perspective view illustrating subsequent steps in themanufacture of the flexible connector of FIG. 5.

DETAILED DESCRIPTION

Referring now to the Drawings, and particularly to FIGS. 2, 3, and 4thereof, there is shown a flexible connector 30 comprising a firstembodiment of the invention. FIGS. 2, 3, and 4 further illustrate amethod of manufacturing the flexible connector.

The flexible connector 30 includes a length of corrugated tubing 32which extends substantially the entire length of the flexible connector30. The length of corrugated tubing 32 may be formed from stainlesssteel, bronze, brass, carbon, monel, other metals, various polymericmaterials, and other materials that will not be adversely affected bythe fluid that will flow through the flexible connector 30. In mostinstances an end piece 34 is provided at each end of the length ofcorrugated tubing 32. Those skilled in the art will recognize the factthat the end piece 34 is representative only and that various types andkinds of end pieces can be utilized in the practice of the invention.The end piece 34 is provided with a proximal end 36 having a pluralityof corrugations 38.

A length of flexible polymeric tubing 40 is initially extended over theexterior of the length of corrugated tubing 32 and is moved axiallythereon sufficiently to expose the distal end thereof. Next, theproximal end 36 of the end piece 34 is engaged with the distal end ofthe length of corrugated tubing 32. Then, the length of flexible tubing40 is moved axially along the length of corrugated tubing 32 until itmoves into resilient gripping engagement with the corrugations 38 of theend piece 34. The function of the length of flexible tubing 40 is toinitially retain the proximal end 36 of the end piece 34 in engagementwith the distal end of the length of corrugated tubing 32.

After the flexible tubing 40 has been positioned to retain the proximalend 36 of the end piece 34 in engagement with the distal end of thelength of corrugated tubing 32, a length of mesh tubing 42 is extendedover the entire length of stainless steel corrugated tubing 32, and overthe entire length of the flexible tubing 40, and over the corrugations38 of the end piece 34. The length of mesh tubing may be formed fromstainless steel, kynas, nylon, various textiles, or other materialsdepending on the requirements of particular applications of theinvention. Assuming that an end piece is positioned at the opposite endof the length of corrugated tubing 32 and that the end piece at theopposite end of the length of tubing 32 also has corrugation similar tothe corrugations 38, the length of mesh tubing 42 also extends beyondthe end of the length of corrugated tubing 32 and over the corrugationsof the end piece positioned in engagement therewith.

Following the positioning of the length of mesh tubing 42 over thelength of flexible polymeric tubing 40 and over the proximal end 36 ofthe end piece 34 and the distal end of the length of corrugated tubing32, a sleeve 44 is positioned over the distal end of the length of meshtubing 42 and in alignment with the length of flexible polymeric tubing40. The results of the foregoing steps are illustrated in FIG. 3. Thesleeve 44 may be formed from stainless steel, copper, bronze, brass,steel, or other materials depending on the requirements of particularapplications of the invention.

Following the assembly steps described in the preceding paragraphs, thepartially finished flexible connector 30 is positioned in a crimping die46. Those skilled in the art will understand and appreciate the factthat the crimping die 46 is diagrammatically illustrated in FIG. 4, andthat the actual crimping die will not necessarily have the appearanceshown in FIG. 4. The function of the crimping die 46 is to crimp thesleeve 44 into gripping engagement with the distal end of the length ofmesh tubing 42, the length of flexible polymeric tubing 40, thecorrugations 38 comprising the proximal end 36 of the end piece 34, andthe corrugations comprising the distal end of the length of corrugatedtubing 32. The crimping of the sleeve 44 therefore permanently retainsthe proximal end of the end piece in engagement with the distal end ofthe corrugated tubing 32. Thus, following actuation of the crimping die46 at the opposite ends thereof, the fabrication of the flexibleconnector 30 is complete.

In the case of flexible connectors intended for low pressureapplications, the length of mesh tubing 42 can be omitted. In suchinstances the sleeve 44 is aligned with the length of flexible polymerictubing 40, the corrugations 38 comprising the proximal end 36 of the endpiece 34, and the corrugations comprising the distal end of a length ofcorrugated tubing 32. The sleeve 44 is then crimped in the mannerdiagrammatically illustrated in FIG. 4 thereby securing the componentparts of the flexible connector in place.

Referring to FIGS. 5 and 6, there is shown a flexible connector 50comprising a second embodiment of the present invention. The flexibleconnector 50 includes a length of corrugated tubing 52 which extendssubstantially the entire length of the flexible connector 50. Theflexible connector 50 will typically include an end piece 54 positionedat each end of the length of corrugated tubing 52. Those skilled in theart will appreciate the fact that the end piece 54 is representativeonly and that various types and kinds of end pieces may be utilized inthe practice of the invention.

Regardless of the type or kind of end piece that is utilized in theconstruction of the flexible connector 50, the end piece 54 ispreferably provided with a proximal end 56 having a plurality ofcorrugations 58 formed thereon. An initial step in the manufacture ofthe flexible connector 50 comprises the engagement of the proximal end56 of the end piece 54 with the distal end of length of corrugatedtubing 52. Thereafter a length of heat shrink polymeric tubing 60 ismoved axially along the length of corrugated tubing 52 until it extendsover the corrugations 58 of the proximal end of the end piece 54 and thecorrugations comprising the distal end of the length of stainless steelcorrugated tubing 52.

Referring specifically to FIG. 6, after the length of heat shrink tubing60 is positioned over the proximal end 56 of the end piece 54 and thedistal end of the length of corrugated tubing 52, a radiation source 62is utilized to heat the length of heat shrink tubing 60. Heating of thelength of heat shrink tubing 60 causes the heat shrink tubing 60 toretract or shrink into rigid engagement with the distal end of thelength of corrugated tubing 52 and the proximal end of the end piece 54thereby securing the distal end of the length of corrugated tubing 52 inengagement with the proximal end of the end piece 54.

The succeeding steps in the manufacture of the flexible connector 50 arethe same as the latter steps in the manufacture of the flexibleconnector 30 as illustrated in FIGS. 2, 3, and 4 and describedhereinabove in conjunction therewith. Thus, the next step in themanufacture of the flexible connector 50 may involve extending a lengthof mesh tubing along the entire length of corrugated tubing 52 and overthe proximal ends 56 of the end pieces 54 comprising the flexibleconnector 50. Thereafter, a sleeve similar to the stainless steel sleeve44 of FIGS. 2, 3, and 4 is positioned over the distal end of the lengthof corrugated tubing 52 (if used), the proximal end of the end piece 54,and the now-shrunk length of heat shrink tubing 60. The final step inthe manufacture of the flexible connector 50 comprises the crimping ofthe sleeve as illustrated in FIG. 4 and described hereinabove inconjunction therewith. In low pressure applications the length of meshtubing may be omitted.

Although preferred embodiments of the invention have been illustrated inthe accompanying Drawings and described in the foregoing DetailedDescription, it will be understood that the invention is not limited tothe embodiments disclosed, but is capable of numerous rearrangements,modifications, and substitutions of parts and elements without departingfrom the spirit of the invention.

1. A method of manufacturing a flexible connector comprising the stepsof: providing a length of corrugated tubing having a distal end;providing an end piece having a proximal end; positioning the proximalend of the end piece in engagement with the distal end of the length ofcorrugated tubing; providing a length of polymeric tubing; extending thelength of polymeric tubing over the proximal end of the end piece andthe distal end of the length of corrugated tubing; utilizing the lengthof polymeric tubing to initially retain the proximal end of the endpiece in engagement with the distal end of the length of corrugatedtubing; providing a sleeve; positioning the sleeve in alignment with thelength of polymeric tubing, with the proximal end of the end piece, andwith the distal end of the length of corrugated tubing; and crimping thesleeve and thereby permanently retaining the proximal end of the endpiece in engagement with the distal end of the length of corrugatedtubing.
 2. The method according to claim 1 wherein the step of providinga length of polymeric tubing is carried out by providing a length offlexible polymeric tubing and wherein the step of utilizing the lengthof polymeric tubing to initially retain the proximal end of the endpiece in engagement with the distal end of the length of corrugatedtubing is carried out by resiliently engaging the length of resilientpolymeric tubing with the proximal end of the end piece and with thedistal end of the length of corrugated tubing.
 3. The method accordingto claim 1 wherein the step of providing a length of polymeric tubing iscarried out by providing a length of heat shrink polymeric tubing andwherein the step of utilizing the length of polymeric tubing toinitially retain the proximal end of the end piece in engagement withthe distal end of the length of corrugated tubing is carried out bydirecting radiation into the length of heat shrink polymeric tubing andthereby shrinking the length of tubing into engagement with the proximalend of the end piece and with the distal end of the length of corrugatedtubing.
 4. The method according to claim 1 including the additional stepof extending a length of mesh tubing around the exterior of the lengthof corrugated tubing, around the proximal end of the end piece, andaround the length of polymeric tubing, and wherein the step ofpositioning the sleeve is carried out by positioning the sleeve aroundthe exterior of the length of mesh tubing.